Introduction:
If you’re a Jeep Wrangler JK owner, you have a robust 4x4 with a strong rear axle - The Dana 44. It’s tough enough for the trails and big tires, yet mysteriously prone to a specific failure: broken or chipped spider gears. So, let’s break down the mystery of these failing gears, why it happens, and what you can do to upgrade your ride without breaking the bank—or your axle.
What Are Spider Gears Anyway?
Spider gears are the small gears inside your differential that allow the wheels to rotate at different speeds. This is crucial for making turns without turning your tires squealing and chirping for help. In a standard setup, spider gears are part of the open differential or the clutch-style limited-slip system in your Jeep’s Dana 44 rear axle. Even Lockers like The Rubicon E- Lockers have spider gears inside but are not failure prone like the Open and LSD options.
Extra Stressors That Can Cause SPidfer Gear Failure:
The Dana 44 is solid, but the factory spider gears are a weak link, especially under the following conditions:
- Off-Road Adventures: When one tire loses traction and the spider gears bear the brunt of sending power to the other wheel, excessive stress can lead to failure.
- Bigger Tires: Upgraded 35-inch or larger tires add extra strain to these components.
- Hard Acceleration or abuse: The sudden torque spikes during hard use can damage the gears.
Our Opinion
Let's cut to the chase here… Our opinion is if the E-Locker variant can withstand all of the above without failure. Something tells me Jeep/Dana chose inferior parts for the open or LSD variant.
We have seen many failures of Jeeps driven by all kinds of different driving styles. We've seen failures from everyone including college girls, older folks and even my own mother. Look I may be a speed freak but I doubt my Mom is out there ripping burnouts and rock bashing and that's the reason her spider gears decided to head out at 40,000 Miles. It's not you; it’s Jeeps fault!
OEM Parts Shortage: No Quick Fix
Tell tale sign its a common issue is when you go to order OEM parts and they say tough luck. Jeep’s Dana 44 spider gears are in high demand, and supply chain delays have left many owners stuck in the shop.
Hold on. Who would put these OEM Failure prone gears back in the vehicle? Not us…
Better Than Stock Upgrades: Eaton Truetrac for the Win
For the daily driver, the Eaton Truetrac limited-slip differential is a game-changer. Here’s why:
- Helical Gear Design: Unlike the factory clutch-style LSD, the Truetrac has no wear-prone clutch packs. This means it’s virtually maintenance-free - Change the fluid as regularly scheduled and keep on trucking.
- Locker-Like Performance: With a little footwork to apply light brake pressure, the Truetrac can simulate a locking differential off-road, giving you more traction when you need
- Snow Performance: While a Locker is the king of off road. You haven’t experienced fear until you’ve driven a locked differential in snow or ice conditions on the street. The locker would cause the rear of the vehicle to spin out of control. While the graceful helical Truetrac puts the power down safely with superior winter traction
- Comparable Pricing: With OEM spider gears hard to find, the Truetrac costs just a hair more—or even less when considering its long-term durability.
If you’re sticking to light trails and daily commuting, the Truetrac offers peace of mind and enhanced performance, no questions asked.
For Hardcore Off-Roaders: Go Big or Go Home
If your Jeep sees more rocks than pavement, consider one of these locker options:
- Eaton E-Locker: An electronic locker that engages at the push of a button, giving you 100% lockup when you need it and open-diff smoothness when you don’t. Eaton is also the manufacturer for the Rubicon E-Lockers.
- ARB Air Locker: Still Push Button Operation but ARB uses compressed air to lock the differential. It’s robust, trail-proven, and a favorite among serious off-roaders. The Downside is it requires an onboard air system in order to operate.
Both are pricier than the Truetrac, but they transform your base model Dana 44 into a trail-conquering beast.
The Bottomline: Don’t Just Replace—Upgrade
When your Dana 44 spider gears call it quits, it’s not the end of the world. Whether you opt for the daily-driver-friendly Eaton Truetrac or go full send with a locking differential, upgrading your Jeep means fewer breakdowns and more adventures. It's a great time to regear while you are deep into the differential. See our guide to re-gearing.
